Sonisolution™ RS Series

aur izonultrasonics.com

With the Sonisolution™ RS Series OEMs have the freedom to design Aurizon’s industry-

leading rotary ultrasonic technology into their systems.

The Sonisoluti on RS Series is available in 20, 30 and 40 kHz frequencies.

Dissected view of the Sonisoluti on RS assembly.

The Sonisolution™ RS Series of rotary ultrasonic sonotrode assemblies

is now available to those with the technical knowledge and ability to

integrate high power ultrasonic capability into their machine designs.

All models of the Sonisoluti on RS are designed for maximum speed capabil-ity with high conti nuous power delivery. Depending on the applicati on, it is possible to reach process speeds up to 800 mpm (2625 fpm). These robust systems have a small footprint and operate eff ecti vely in any orientati on.

The Sonisoluti on RS uses less power during operati on than other energy-consuming processes for bonding and sealing, off ering the consumer an op-portunity to save on energy costs. Also, the technology works instantaneously when powered on, eliminati ng stop/start delays due to heat up and cool down, thereby increasing producti vity.

With many more benefi ts for your customers, such as the capabil-ity to reduce raw materials, increase process speed, improve product quality and decrease equipment maintenance, the Sonisoluti on RS is the ideal tool to add to your repertoire.

Maximize capabilities for your customers... off er them an improvement to pressure, thermal and adhesive processing. Maximize capabilities for your customers...

off er them an improvement to pressure, thermal and adhesive processing.

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NONWOVENS: Ultrasonic technology is used to bond, att ach, emboss and laminate nonwoven materials. Aurizon has also engineered soluti ons for feature att achment, elasti c entrapment, core bonding, acquisiti on layers and back sheets.

FILMS: Ultrasonics is used for a broad range of sealing and process soluti ons including fl ow wrapper, VFFS and HFFS machinery.

OTHER: Coated paperboard, corrugated plasti c and fi lter media have been converted using our rotary ultrasonic technology.

SEALING ELASTIC PANELCONSTRUCTION

SHAPE CUTTING FEATURE ATTACHMENT

EMBOSSINGZIPPER ATTACHMENTAND CRUSHING

Aurizon rotary ultrasonic equipment is ideal for industrial applications that attach, bond, cut, seal or otherwise convert nonwovens, fi lms and other thermoplastics.

CRUSHING/SCORING BONDING

WHAT ARE SOME COMMON ULTRASONIC PROCESSES?

...AND MORE!

WHICH MATERIALS ARE BEST FOR ULTRASONIC PROCESSING?

CONVERTER

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Sonisolution™ is a trademark of Aurizon Ultrasonics, LLC

Impact force to radial surface of rotary horn does not damage the converter.

THE ROTARY DIFFERENCE

• Higher, continuous power delivery results in faster process speeds.

• System components can operate in contact with other surfaces.

• Rolling contact enables better sealing over varying material thicknesses.

• Eff ective with a broad array of polymers and materials.

• Dual rotary components squeeze residual material out of the seal zone.

• Cross-directional bond width is only limited by process design.

Key Advantages...increasing process throughput, reducing material costs and saving energy..

Ultrasonic processing is a fast, clean, effi cient process that consumes less energy than heat-based processes.

No solvents, adhesives, mechanical fasteners or other consumables are required.

Within a fracti on of a second, materialin contact with an acti vated sonotrode becomes molten, forms around a patt erned anvil and creates a “wall” of solidifi ed polymer as it cools. The resulti ng bond is shown magni-fi ed in the images to the right.

One of the key advantages of the rotary sonotrode is the ability to achieve very high amplitudes and operate in contact with other surfaces (patt erned anvils) without converter failure. This characteristi c is especially valuable when processing extremely thin materials since the components can operate in contact mode and generate the forces required for high-speed bonding of lightweight materials.

Rolling contact enables better sealing over varying material thicknesses.

Dual rotary components squeeze residual material out of the seal zone.

The ultrasonic generator supplies high fre-quency electrical energy to the converter. The converter is a piezoelectric transducer that vibrates in response to applicati on of an alter-nati ng voltage, changing electrical energy to mechanical energy at a specifi ed frequency.

Att ached to the converter are the booster and sonotrode. These amplitude modifying devices can be designed to increase or decrease the amplitude of the vibrati on supplied to the rest of the system and eventually to your pro-cess. The booster transmits longitudinal moti on from the converter to the sonotrode and either amplifi es or att enuates that moti on. The sonotrode transforms longitudinal moti on to radial and de-livers energy to the material being processed.

CONFIGURATION EXAMPLES

RS ASSEMBLY - FLAT ANVIL

MULTIPLE SPLIT RS ASSEMBLIES-INDEPENDENT ROTARY ANVILS

MULTIPLE RS ASSEMBLIES -COMMON ROTARY ANVIL

SPLIT RS ASSEMBLY - ROTARY ANVIL

Air Flow Sensor

Cooling Manifold

Converter

Sonotrode

Booster

Slip Ring

BearingHousing

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Sonisolution RS Components sonic stack—converter, booster, sonotrode

cooling manifold, bearing housing and slip ring

Power Generator Included (Not Shown)See page 6 for information

on ultrasonic generators.

The Sonisolution™ RS includes all essential components required to produce ultrasonic energy.

With the Sonisolution™ RS Series... OEMs can design the ultrasonic energy source into their system.

With the Sonisolution™ RS Series... OEMs can design the ultrasonic energy source into their system.

Generator selection should consider power needs to accommodate long term production requirements.

Ports on the back of the iQ LE include the power cable, the power switch circuit breaker, Ethernet/IP port, a cus-tom confi gurable inter-connect panel with 15 and 25 pin inputs, ultrasound and RS232 Serial confi gurati on port and a panel for expansion.

Generator selection should consider power needs to accommodate long term production requirements.

iQ Auto Plus mounted verti cally with heat sink.

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The iQ LE generator is customized for applicati ons that use Aurizon’s rotary ultrasonic horns. Using the available system control inputs and status output signals, it can be easily integrated with automated ma-chinery. The iQ LE must be horizontally mounted.

The iQ Auto Plus generator was specifi cally designed for easy integrati on into automated processes. Com-pact in size, it provides the highest power densityin the smallest package. The unique modular design allows for custom confi gurati ons.

iQ Auto Plus Seriesapproximate weight 15.4 kg (34 lbs)approximate weight 4.6 kg (10 lbs)

Operati onal ultrasonic generators should be kept in a clean, temperature controlled environment between 10-22 degrees C (50-72 degrees F). The iQ LE should be mounted with a space allowance of at least 125 mm (5 in) on both sides of the generator chassis for adequate air circulati on and a minimum of 76 mm (3 in) in the back for cable clearances.

The iQ Auto Plus can be set on its feet or mounted verti -cally as shown. All connecti ons are located on the front panel of this series and includes a PC user interface tool via a front panel USB connector. The I/O status monitor allows for quick troubleshooti ng and analysis in real ti me.

iQ LE Series

Sonisolution™ is a trademark of Aurizon Ultrasonics, LLC

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While the OEM will incorporate rotary ultrasonics into their machines and support customer installati ons, Aurizon is available to provide additi onal services (described on the following page).

The Sonisoluti on RS is an integrated elecromechanical device that must be controlled properly to produce quality results. Required process control typically include rotati onal motors and drives, conveyors, web guides, etc. Other components necessary to the process include PLC controls for nip open and close functi onality and a blower for supplying cooling air whenever there is output from the generator.

PROCESS CONTROL

The design of the energy guide (anvil) is dependent on the desired applicati on and your main objecti ves. Should you opti mize bond strength? Producti on speed? Need a hermeti c seal? Are aestheti cs most important? You must consider the properti es of the materials being pro-cessed and geometry of the anvil patt ern when designing your energy guide.

ENERGY GUIDE

SERVICE & SUPPORT

When designing ultrasonic equipment into your machine, manufacturers must consider the following.

We are here to help you along the way...put our technology and capabilities to work for you.

The structure for mounti ng should support the device when rotati ng and control any vibrati onal movement caused by the running equipment. The actuati on mechanism controls the movement of the Sonisoluti on RS assembly to bring it into close contact with the anvil. This mechanism allows the appropriate force to be applied to the materials being processed in your specifi c applicati on. There is an opti onal guard assembly feature available; depending on the applicati on and safety concerns of the customer.

MOUNTING & ACTUATION

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Aurizon Ultrasonics off ers initi al proof-of-principle testi ng to determine whether our technology can add value in your applicati on. The lab is staff ed with a team of engineers and scienti sts with years of experience testi ng applicati ons for rotary ultrasonic technology. The lab provides support in a multi tude of ways. Visit htt ps://aurizonultrasonics.com/support/testi ng-trials.com to learn more.

ADVANCED ULTRASONIC LAB SERVICES

A cornerstone of Aurizon’s philosophy is to provide an unsurpassed level of service to the ultrasonic market. Our ultrasonic engineers and pro-cess specialists have decades of experience and can assist you or your customers with additi onal equipment process integrati on and start-up support. Technical experts are also available for assistance with trouble-shooti ng and equipment repair and/or refurbishment.

Aurizon off ers an Authorized System Integrator (ASI) technical training program to OEMs interested in obtaining a deeper understanding of ultrasonics. While this program is not required to integrate our equipment, it provides valuable insight into the intricacies of ultrasonic technology and would be helpful to those providing support to installed systems. Training consists of a hands-on series of sessions focused on mechanical and electrical operati on, system requirements and troubleshooti ng techniques.

ULTRASONIC TECHNOLOGY TRAINING

Aurizon can help you with applicati on engineering of Aurizon equip-ment to your process requirements - bonding, cutti ng, simultaneous bonding and cutti ng, embossing, laminati ng, and more. We can also provide design engineering of custom tooling and Finite Element Anal-ysis of tooling and mounti ng structures.

APPLICATION AND DESIGN ENGINEERING

CUSTOMER SUPPORT

Sonisolution™ is a trademark of Aurizon Ultrasonics, LLC

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Aurizon offers high power ultrasonic processing systems at frequencies of 20, 30 and 40 kHz. The lower the frequency, the larger the compo-

nents become and the more total power that is available to be delivered.

Your technical contact can help you determine which frequencies are appropriate for specific applications.

FREQUENCY

SONOTRODE WIDTH

(maximum bond width)

SONOTRODE DIAMETER

BEARING HOUSING HEIGHT/ WIDTH

CLEARANCE NEEDED ON

EACH SIDE OF SYSTEM

BOOSTER GAIN

AVAILABLE POWER

TOP PROCESS SPEED

(application specific)

APPROX. MACHINE DIMENSIONS

WIDTH LENGTH DEPTH

20 kHz3”

75mm

6.7”-6.9” 170 mm- 175 mm

6.1” 155 mm

0.3”-0.4” 7.6-10.2

mm

1.0, 1.25,

1.5, 2.03600W

2625 fpm 800 mpm

9.1” 232 mm

24.2” 614 mm

8.4” 212 mm

30 kHz2”

50mm

4.5”-4.6” 114 mm- 117 mm

3.9” 100 mm

0.28”-0.33” 7.2-8.4 mm

1.0, 1.5750W

1800W

1500-2000 fpm

450-600 mpm

7.2” 184 mm

19.8” 502 mm

6.9” 175 mm

40 kHz1.33” 34mm

3.4”-3.5” 86 mm- 89 mm

3.9” 100 mm

n/a1.25, 1.5,

1.75, 2.0

600W 750W

1200W

750 fpm 225 mpm

5.9” 150 mm

16.5” 420 mm

6.6” 169 mm

For each application, there are several variables to consider that will determine the appropriate system combination.

All dimensions are approximate and do not include additional components.

APPLICATION FREQUENCY

Nonwovens 20-30 kHz

Films 30-40 kHz

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aurizonultrasonics.com

Aurizon Ultrasonics, LLC

900 West Kennedy AvenueKimberly, WI 54136

Phone: +01 920-750-5080Toll-Free: 1-877-321-3718

Email : info@aurizonultrasonics .com

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